Production of multilayer productive coverings on conventional dip molding lines

ABSTRACT

Method of making a multilayer protective covering such as a surgical glove, finger cot or condom. Mold with a first layer is dipped into a gas-releasing solution which comprises a release agent, a blowing agent, and/or a coagulant. The mold is then dipped into a layer-forming solution to form a second layer. Heat is applied and gas forms between the layers, separating the layers. An antimicrobial solution may replace gas between the layers.

This is a continuation-in-part of copending application Ser. No.678,838, filed Apr. 1, 1991, which is a continuation-in-part of Ser. No.422,913, filed on Oct. 17, 1989 (now abandoned), which is acontinuation-in-part of Ser. No. 359,474, filed on May 2, 1989 (nowabandoned).

This invention relates to protective coverings (e.g., gloves andcondoms) for human body members, and methods for making such protectivecoverings. More particularly, this invention relates to coverings suchas protective gloves which may be used for various purposes, including,for example, surgery or other medical procedures, or protection fromhazardous chemical substances.

The design of protective gloves represents a struggle of competinginterests. To increase the protective nature of the glove intuitivelyrequires increasing the thickness of the glove material. However, byincreasing the thickness of the glove material, the sense of feel forthe wearer of the gloves is increasingly hampered. Thus, the glovedesigner must find a suitable compromise between safety and sense offeel.

This problem is particularly acute in the area of surgical gloves. Thesense of feel in the hands of a surgeon is important for the properhandling of delicate instruments and the proper execution of precisesurgical procedures. However, it is also desirable that the surgeon beprotected from biohazardous agents which the surgeon may be exposed tofrom the patient. For example, the surgical patient may carry virusessuch as HIV (Human Immunodeficiency Virus) or hepatitis. During surgery,the surgeon's gloves are frequently cut or punctured, exposing thesurgeon to infection.

Also, it is desirable to protect the patient from germs on the surgeon'sor technician's hands. Although medical personnel, of course, typicallyscrub their hands before performing surgical procedures, some germs mayremain and be exposed to the patient upon puncturing or tearing thesurgical gloves.

Surgical gloves known to the Applicant are generally made of latex,vinyl, or neoprene, i.e. thin elastic materials which provide reasonabletear resistance and allow for satisfactory sense of feel. However, thegloves may be easily torn or punctured with sharp surgical instruments.Furthermore, it is difficult for the surgeon to detect a small tear orpuncture in the glove material during surgery since such a puncture isdifficult to see, especially if the gloves are covered with a patient'sbody fluids. Thus, the surgeon has little warning of exposure.

In the chemical or hazardous material preparation and handling area,disadvantages in present gloves also exist. Although the sense of feelfor these areas may not be as important as that for the surgeon, thereis also often a risk or danger even with thicker protective gloves. Theglove material may be degraded or penetrated after a period of time byvarious chemicals which the chemist handles.

Protective coverings for other parts of the body also exist. Forexample, finger cots (i.e. glove-like coverings which cover only onefinger) are used in medical procedures, particularly in rectal andvaginal examinations. Condoms are used to cover the male reproductiveorgan during intercourse. In addition to the obvious purpose of a condomto trap semen and thereby minimize the possibility of pregnancyresulting from intercourse, condoms are also used to protect thepartners from infections by sexually transmitted diseases. This hasbecome increasingly important over recent years in preventing the spreadof HIV.

In these and other protective coverings, similar problems and concernsexist, i.e. danger of tearing or ripping the covering balanced againstthe desire for sensitivity.

Thus it is a general object of this invention to provide protectivecoverings which address the disadvantages experienced by theabove-described coverings.

In one broad aspect, the present invention provides a protectivecovering for a human body member, the protective covering having aninner and outer layer. A layer of protective solution (such as anantimicrobial solution) is disposed between the inner and outer layers,and an impermeable seal is provided between the layers to contain theprotective solution therebetween. The solution layer is preferably lessthan about 0.12 millimeter (mm) average thickness, such that capillaryforces are exerted on the two covering layers, thereby providing amechanical-like coupling between the two covering layers.

The term "protective covering" is used to mean any covering used toprotectively cover a human body member. The term "human body member" isused broadly to include all limbs and external protrusions of the humanbody, e.g., fingers, hands, arms, toes, feet, legs, head, penis, etc. Inmany situations, a human body member may be exposed to biohazardoussubstances such as infected body fluids, or hazardous chemicals.Coverings are often used to protect body members from exposure tohazardous substances. Thus, the term "protective covering" includes suchitems as gloves, finger cots, condoms, and the like.

In a preferred embodiment, the present invention provides a surgicalglove having an inner and outer layer. A layer of antimicrobial solutionis disposed between the inner and outer layers, and an impermeable sealbetween the layers is provided. As stated above, the solution layer isless than 0.12 mm in average thickness to provide a mechanical-likecapillary coupling between the glove layers.

To maximize the capillary force exerted by the liquid layer, the averagethickness of such layer is preferably between about 0.01 and 0.09 mm,most preferably between about 0.025 and 0.05 mm. Further, the liquidlayer is preferably of substantially uniform thickness.

The term "antimicrobial solution" means herein a solution, typicallyaqueous, capable of killing or inactivating infectious agents, such asbacteria or virus. Thus, the term includes, for example, virucides,bactericides, antiseptic solutions, antiviral solutions, antibacterialsolutions, etc. The term also includes spermicidal solutions,particularly applicable when the protective garment provided by theinvention is a condom. The spermicidal solution used is preferablyadditionally virucidal and/or bactericidal.

The term "impermeable seal" is used to mean a seal which issubstantially both fluid-tight and air-tight. The seal should befluid-tight to prevent leakage of the protective solution between thelayers, and should be air-tight to facilitate mechanical couplingbetween the two layers resulting from capillary forces exerted by theprotective solution.

Typical virucides known in the art which may be suitable for use withthe present invention include, for example, alcohols, ethers,chloroform, formaldehyde, phenols, beta propiolactone, iodine, chlorine,mercury salts, hydroxylamine, ethylene oxide, ethylene glycol,quaternary ammonium compounds, enzymes, and detergents.

The glove of this invention can provide improved protection over singlelayer surgical gloves. If the layers of the glove are punctured or tornduring surgery, the antimicrobial solution releases and attacksinfectious agents before reaching the surgeon's hands, thus protectingthe surgeon during operating procedures. Furthermore, when the glovebecomes punctured during use, it may act to protect the patient fromexposure to germs which may exist on the surgeon's hands. Tearing orpuncturing the glove may provide quick and thorough release of theantimicrobial solution disposed between the layers.

Applicant has found that sense of feel is not significantly diminishedby the double layers. By providing a solution layer of thickness in theranges described above, capillary forces exerted by the liquid solutionprovide a mechanical-like coupling between the glove layers, so that thesense of feel for the wearer of the gloves is not significantlydiminished.

In a preferred embodiment, the antimicrobial solution comprises avirucidal solution, such as aqueous nonoxynol-9. This substance is aneffective virucide against such viruses as HIV and hepatitis, and thusprovides a glove being particularly useful for performing medicalprocedures on infected patients. Preferably, the aqueous nonoxynol-9 hasa concentration of between about 0.05% and 5% (volume/volume). Mostpreferably, the concentration is between about 0.25% and 1%(volume/volume). It is known that a concentration in this range iseffective for killing viruses. Higher concentrations can also be usedbut may be irritable if contacted with the eyes.

In another embodiment, the antimicrobial solution comprises abactericidal solution. Of course, the antimicrobial solution couldinclude both virucidal and bactericidal agents.

In a preferred embodiment of a surgical glove provided by the presentinvention, the antimicrobial solution includes a dye. This embodimentprovides an effective means for showing the surgeon the precise locationof a tear or puncture in the glove. Thus, if the outer layer of theglove is punctured, the dye will seep out of the puncture hole and stainthe area around the hole. If the inner layer is also punctured, the dyewill seep through the inner hole and stain the surgeon's hand at thelocation of the puncture. This provides the surgeon the precise locationof exposure so that the surgeon can decontaminate the area of puncture.

Many suitable dyes are available for use with this invention. A dyeshould preferably be selected which is FDA approved for internal andexternal use so as not to harm the patient or surgeon. Preferably, thedye is selected so that its color is easily detectable in a bloodenvironment. Suitable dyes incudes FDA approved FD&C colors, forexample, FD&C Blue #1 (MERCK Index #1350), FD&C Blue #2 (MERCK Index#4835), and FD&C Green #3 (MERCK Index #3876). These three dyes areparticularly preferred since they have FDA approval for use in food,drugs, and cosmetics, and provide good indications of puncture in usewith the present invention due to their intense colors (in relativelylow concentrations). Preferably, the concentration of the dye in theantimicrobial solution is between about 0.3 to 0.5 grams/liter,providing a good compromise between economics and tear indication.

Many dyes are also bactericidal and thus provide the further function ofattacking infectious agents. Another advantage provided by use of suchdyes is that they can not generally be washed off with water. Thus, ifthe glove is punctured and the user's hand is stained by the dye, hemust use alcohol to remove the stain, alcohol also being a bactericide.Thus, the area of the puncture is decontaminated while the dye stain iswashed off.

Preferably, the volume of the antimicrobial solution disposed betweenthe layers of an average-sized glove (e.g. size 7.5-8.5) is betweenabout 2 and 3 milliliters. For a size 8.5 glove (surface areaapproximately 650 cm²), this volume of liquid provides a solution layerthickness of around 0.03 to 0.05 mm, thereby providing good capillarycoupling between the glove layers.

In a preferred embodiment, the inner and outer layers are made of latex.Alternatively, the layers may comprise vinyl or neoprene. Latex providesadequate tear resistance for surgical procedures and allows for a goodsense of feel for the wearer.

In a preferred embodiment, the inner layer may include a rough outersurface. Alternatively, the outer layer may include a rough innersurface. This may provide the advantage of preventing the antimicrobialsolution from being completely squeezed away from any glove areas whichare compressed during normal usage.

For applications when one may be exposed to harmful chemicals, such asduring handling or preparation of chemicals or other hazardoussubstances, another embodiment of the present invention provides aprotective glove. The protective glove includes an inner layer, an outerlayer, an impermeable seal between the inner and outer layers, and alayer of neutralizing solution (thickness as described above) disposedbetween the inner and outer layers.

The neutralizing solution disposed between the inner and outer layerscan be appropriately selected for the particular application for whichthe glove is to be used. Preferably, the neutralizing solution should beselected such that if the outer layer of the glove is punctured orpermeated, the neutralizing solution will neutralize the chemicals towhich the glove is exposed and thus protect the hands of the wearer ofthe glove.

For example, if a chemist is to be handling acids, the neutralizingsolution selected should be a basic or buffering solution which couldneutralize the acid upon puncture of the glove before reaching thechemist's hands. As another example, if a person were handlingneurotoxins one might place appropriate enzymatic agents between theglove layers which could cleave the neurotoxins upon contact.

Since the sense of feel for a chemist is usually not as critical as thatfor a surgeon, a thicker layer and more protective material than latexis preferably selected for the protective glove. For example, the innerand outer layers may be made of neoprene, nitrile, or any other suitablematerials which are resistant to the types of materials to be handledand which are resistant to tearing or puncture.

Since the appropriate neutralizing solution disposed between the layersmay vary depending upon the chemicals or materials to be handled, theseal between the layers preferably includes a zip lock seal. In thismanner, the user of the glove can temporarily open the seal, place theappropriate neutralizing solution between the glove layers, and resealthe glove.

Additionally, the material between the glove layers may included a pH orother indicator which would change colors after a passage of time toindicate that the neutralizing agent has been used up, such that thegloves may no longer be effective. Upon such indication, the user couldreplace the old gloves with a new pair.

In a preferred embodiment, the protective solution includes a dye togive a visible warning upon release if the glove is leaking or becomespunctured. That is, the dye upon release will stain the area ofpuncture.

Another embodiment of the present invention provides a surgical gloveincluding a dye associated with the glove in such a manner as to producea visible stain if the glove becomes punctured or torn at the locationof such puncture or tear.

The invention also extends to a finger cot having an inner layer, anouter layer, an impermeable seal between the layers, and a layer ofantimicrobial solution (thickness as described above) disposed betweenthe layers. The finger cot is substantially similar to the surgicalglove described above, except that the finger cot is configured and usedto cover only a single finger as opposed to an entire hand. Thepreferred embodiments of materials discussed above in relation tosurgical gloves also apply to finger cots. Thus, for example, theantimicrobial solution of the finger cot preferably includes a dye.

The invention further provides a condom having an inner and outer layer,an impermeable seal between the layers, and a layer of antimicrobialsolution (thickness as described above) disposed between the inner andouter layers. Preferably, the antimicrobial solution comprises aspermicidal solution, such as nonoxynol-9. Nonoxynol-9 is particularlypreferred since it also acts as a virucidal agent for protection againstHIV and hepatitis.

One potential problem which can arise with the double (or multi) layerprotective coverings provided by this invention is that the two layersmay tend to slip on each other during use. This potential problem ismost likely to arise when the covering is inserted into and removed froma tight passage, as will typically occur when using a glove, finger cotor condom. To reduce this problem, the layers of the covering may besealed (e.g., by heat stamping or gluing) at a plurality of points,thereby physically adhering the two layers at those points. This willreduce the likelihood of slippage of the covering during use.

It should be appreciated that the protective ability of the covering maybe reduced at the sealed points, since a puncture of the covering atthat precise location might not cause the release of the protectivesolution disposed between the layers. This is not likely to present asignificant concern in relation to condoms and finger cots, since sharpobjects are not generally encountered when using those items.Nevertheless, the potentially reduced protection of the covering shouldbe appreciated and considered when selecting the number and pattern ofsealed points on the covering.

Another broad aspect of this invention provides methods for makingprotective gloves, e.g., surgical gloves. One such method comprises thesteps of providing a first glove on a hand-shaped form, the first glovehaving a hand portion and a wrist portion; dipping the first glove intoan antimicrobial solution; placing a second glove having a hand portionand a wrist portion on the hand-shaped form over the first glove, andsealing the wrist portions of said gloves together, such that theantimicrobial solution is contained as a layer between the first andsecond gloves, the solution layer having an average thickness of lessthan about 0.12 mm.

A second method provided by this invention comprises the steps ofproviding a first glove on a hand-shaped form, the first glove having ahand portion and a wrist portion; placing a second glove on thehand-shaped form over the first glove, the second glove having a handportion and a wrist portion; placing an antimicrobial solution betweenthe first and second gloves, and sealing the wrist portions of saidgloves together, such that the antimicrobial solution is contained as alayer (thickness as described above) between the first and secondgloves.

The term "hand-shaped form" is used herein broadly to mean any structurehaving the shape of a human hand, e.g., a conventional ceramic or metalformer. The term also encompasses an actual human hand.

The initial step in each of the two above-described methods comprisesproviding a first glove on a hand-shaped form. This can be accomplished,for example, by obtaining a glove from a commercial or other availablesource and stretching the glove over a hand-shaped form. Alternatively,it can be accomplished singly or repeatedly by dipping a hand-shapedform into latex or other material to coat the form with a layer of thematerial, and drying and/or curing the layer to form the first glove onthe form.

A third method for making a protective glove provided by this inventioncomprises the steps of providing a first glove having a hand portion anda wrist portion; exposing the exterior surface of the first glove to avacuum to expand said glove; placing an antimicrobial solution on theinterior surface of the first glove; inserting a second glove having ahand portion and a wrist portion into the expanded first glove; removingthe vacuum from the exterior surface of the first glove; and sealing thewrist portions of the first and second gloves together to contain theantimicrobial solution as a layer (thickness as described above) betweenthe first and second gloves.

The first and second gloves in all three methods described above may be,for example, conventional latex surgical gloves, or gloves made of someother material.

This invention provides a fourth method for making a protective glovecomprising the steps of providing an enclosed bag or balloon (i.e., anenveloped sheet of material) having two opposing hand-shaped sections;puncturing one of the hand-shaped sections; applying a vacuum to theinterior of the punctured hand-shaped section such that the opposinghand-shaped section is drawn into said punctured section; releasing thevacuum; injecting an antimicrobial solution between the two hand-shapedsections and sealing the puncture, such that the antimicrobial solutionis contained as a layer (thickness as described above) between saidsections. The enclosed bag of material may be produced in a negativeform based on two negative hand-shaped spaces.

A fifth method of making a protective glove includes dipping asubstantially hand-shaped form (e.g., a ceramic former) into a firstlayer-forming solution to form a first layer. The first layer is dippedinto a gas-releasing solution that releases gas when heated. The firstlayer is then dipped into a second layer-forming solution to form asecond layer. Heat is applied to either the first or the second layers(or both) such that gas is released from the gas-releasing solution toform a gas-filled layer separating the first and second layers. The gasmay then be replaced with an antimicrobial solution. The first andsecond layers may be sealed together at the wrist. The gas-releasingsolution may include a release agent such as polydimethylsiloxane, acoagulant such as calcium nitrate, and/or a blowing agent such as sodiumhydrogen carbonate or ammonium carbonate.

The methods described above to make gloves may also be used to makecondoms or finger cots by varying the shape of the forms used.Substantially the same materials and methods apply for condoms andfinger cots.

A preferred embodiment of each of the above-described methods comprisesan additional step of adhering the two hand portions or sectionstogether at a plurality of points. This provides the advantage ofrestricting slippage of the two hand portions or sections during use ofthe glove.

The hand portions or sections may be adhered together in a variety ofways, e.g., by glue or double-sided adhesive tape.

In a preferred embodiment, the adhering step is accomplished byspot-vulcanizing the hand portions together at a plurality of points. Inthis embodiment, the first and second gloves (or the enclosed bag in thefourth method described above) may comprise unvulcanized (i.e., greenstrength) latex. After spot-vulcanizing the hand portions or sectionstogether at the desired points, the entire glove assembly may then bevulcanized. Due to the high temperature involved in such vulcanization,the antimicrobial solution disposed within the glove assembly preferablycomprises a degassed liquid, so that the liquid will not emit gas duringthe vulcanization step.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention is now described by reference to the appended drawingswhich illustrate particular preferred embodiments of this invention.

FIG. 1 is a side view of a glove prepared according to the presentinvention.

FIG. 1A is an enlarged, fragmentary, sectional side view illustratingthe impermeable seal between the inner and outer layers of the glove ofFIG. 1.

FIG. 2 is a fragmentary, sectional side view illustrating an alternateimpermeable seal between the inner and outer layers of a glove inaccordance with the present invention.

FIG. 3 is also a fragmentary, sectional side view showing anotheralternative of an impermeable seal.

FIG. 4 is a side view of a condom prepared according to the presentinvention.

FIG. 5 is a fragmentary, sectional view of the condom taken at theposition shown in FIG. 4.

FIG. 6 is a side view of a finger cot prepared according to the presentinvention.

FIG. 7 is a schematic diagram of the apparatus used in the examplebelow.

FIG. 8 is a plot of the experimental results of the example below.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, a preferred embodiment of the present inventionis shown. A double layer glove 10 is illustrated having an inner layer12, an outer layer 14, an impermeable seal 16 between the inner layer 12and the outer layer 14, and a protective solution 18 disposed betweenthe inner layer 12 and the outer layer 14. The solution layer 18 has anaverage thickness of less than about 0.12 mm, preferably between about0.01 and 0.09 mm, even more preferably between about 0.025 and 0.05 mm,thereby maximizing the capillary coupling force between glove layers 12and 14.

This glove is suitable for a broad range of applications, depending uponthe selection of material for the inner and outer layers 12 and 14 andthe protective solution 18. For use as a surgical glove, the inner andouter layers 12 and 14 are preferably made of latex. For such a surgicalglove 10, protective solution 18 preferably comprises an antimicrobialsolution. The antimicrobial solution preferably comprises a virucidalagent such as nonoxynol-9. The antimicrobial solution may also oralternatively include a bactericidal solution.

In a preferred embodiment, the antimicrobial solution 18 includes a dye.The dye will stain the area surrounding a puncture or tear in the glove,giving the surgeon a visual means for detecting areas of exposure.

In a preferred embodiment of the invention, the antimicrobial solutioncomprises nonoxynol-9 having a concentration of between about 0.05%-5%(v/v), most preferably about 0.5% (v/v), and a dye comprising FD&C Blue#1 having a concentration of between about 0.3 and 0.5 g/l.

In one preferred embodiment, the inner layer 12 includes a rough outersurface (i.e., the surface exposed to the antimicrobial solution 18).Single layer latex gloves are commercially available, wherein one mayspecify the roughness or coarseness of the surfaces of the glove.

In a preferred embodiment, the layers 12 and 14 are sealed (i.e.,adhered) together at a plurality of points to reduce the likelihood thatthe layers slip on each other during use. As shown in FIG. 1, thefingers of the glove 10 may include a plurality of points 17 where thelayers 12 and 14 have been adhered together. This feature isparticularly advantageous when the fingers are used to explore orexamine tight places. As illustrated in FIG. 1, the adhered points 17are preferably located at the dorsal midpoint of the distal, middle, andproximal phalanges of each finger. By locating the points at the dorsalportion of the glove 10, sensitivity is not substantially impaired, butdisassembly of the layers is restricted.

The adhered points may be formed by heating and pressing the inner andouter layers together at the desired places for a sufficient length oftime for a seal to form. Alternatively, the layers may simply be gluedtogether, or stuck together with double-sided adhesive tape, availablecommercially from, e.g., the 3M Company.

The impermeable seal between the inner and outer layers 12 and 14 maytake a variety of forms as illustrated in FIGS. 1A, 2 and 3. In FIG. 1A,the inner and outer layers 12 and 14 proximate the wrist area of theglove have been vulcanized or heat stamped to provide an impermeableseal 16. The seal 16 can be formed by simply applying heat and pressingthe inner and outer layers 12 and 14 together around the circumferenceof the wrist area for a sufficient length of time for a seal to form.

Alternatively, inner layer 12 and outer layer 14 may be glued togetherto form an impermeable seal 20 as shown in FIG. 2. For example, withrespect to a latex surgical glove, a latex glue can be convenientlyused. Such glues are commercially available, e.g., 2141 Rubber Adhesivefrom the 3M Company. Alternatively, commercially available rubbercements can be used to create the seal between the layers. As a furtheralternative, shown in FIG. 3, inner layer 12 and outer layer 14 may beformed of a continuous sheet of material such that an impermeable seal22 is provided by the roll connecting the inner and outer layers 12 and14. Other fluid-tight seals may be used, for example, tape adhesive onboth sides or a zip lock seal.

For chemical handling or preparation applications, the inner and outerlayers 12 and 14 shown in FIG. 1 preferably comprise either neoprene ornitrile. A neutralizing solution 18 is disposed between the inner andouter layers 12 and 14. Furthermore, the seal 16 is preferably a ziplock type seal, so that the user can select and place an appropriateneutralizing solution between the layers depending upon the particularchemicals to be handled.

Several methods of preparing gloves provided by the present inventionwill now be described. These preparations will be discussed in thecontext of surgical gloves, although it should be understood thatanalogous preparations may be performed for other types of gloves andprotective coverings.

In one preferred method, one places a first glove on his hand (orhand-shaped form). This first glove will eventually form the inner layerof a double-layer glove. The preparer of the glove dips his gloved handinto an antimicrobial solution and removes his hand from the solution.The preparer then places a second glove on his hand over the firstglove. The second glove thus forms the outer layer of the double-layerglove. To form an impermeable seal between the first and second gloves,the preparer may peel a portion of the second glove away from his wrist.The preparer then applies glue or double adhesive tape to the outersurface of the first glove around the periphery proximate the wrist ofthe glove. The preparer then peels the wrist area of the second gloveback over the first glove to form a glue seal.

In another preferred method, one places a first glove on a hand-shapedform. Next, glue or double-sided adhesive tape is placed at variouspoints on the exterior of the first glove. Next, a second glove isplaced over the first glove, whereby the glue or double-sided adhesivetape adheres the two gloves together at a plurality of points. Next, anantimicrobial solution is placed between the first and second gloves,e.g., by injecting the solution therebetween. Finally, the wristportions of the two gloves are sealed (e.g., with glue or double-sidedadhesive tape) to contain the antimicrobial solution between the twogloves.

In another preferred method, one dips a hand-shaped form (e.g., aceramic former) in latex to form a layer of latex on the form. When thelayer is sufficiently dry, a first "green" glove is thereby provided onthe hand-shaped form. A second green strength (i.e., unvulcanized) latexglove is placed over the first glove, and a degassed antimicrobialliquid is disposed between the two gloves. (This may be accomplishedeither by dipping the first glove in the degassed antimicrobial liquidprior to applying the second glove, or injecting the degassedantimicrobial liquid between the two gloves after applying the secondglove). Next, the wrist portions of the two gloves are adhered togetherby vulcanization to form an impermeable seal, thereby containing theantimicrobial solution between the two gloves. The two gloves may beadhered together at a plurality of points-by spot-vulcanizing themtogether at desired spots. Finally, the entire glove assembly isvulcanized.

Another suitable method of preparing a double-layer glove includesproviding a first glove and exposing the exterior of the first glove toa vacuum environment. This first glove will eventually form the outerlayer of the double-layer glove provided by the present invention. Forexample, the first glove may be inserted into a box through a boxopening, wherein the wrist area of the first glove is temporarily sealedover the opening of the box in an air-tight arrangement. A vacuum isthen applied to the interior of the box. This operates to expand thefirst glove like a balloon.

Next, a selected amount of antimicrobial solution is placed into theinterior of the first glove. A second glove, which will form the innerlayer of the double-layer glove, is now inserted into the expanded firstglove. Preferably, the second glove is provided on a production form inthe shape of a hand so that the second glove may be convenientlyinserted in proper finger alignment with the first glove. The vacuum isthen released and the first glove is released from the box opening. Thefirst and second layers are then sealed proximate the wrist area.

A double-layer glove may be formed from a single piece of material, andthus provide a glove having a rolled seal as illustrated in FIG. 3. Tomake such a glove, a sheet of latex is first formed having two opposingglove-shaped sections. Such a sheet may be made using a negative form.Thus, one half of the sheet is in the shape of a hand, and the otherhalf of the sheet is in the shape of an opposing hand. A puncture ismade in one of the opposing hand sections and a vacuum is applied to theinterior portion of that hand section. Due to the vacuum, the opposinghand section will be drawn into the first hand to provide a double layerglove. The hand section in which the puncture was made and vacuumapplied forms the outer layer, and the opposing hand section forms theinner layer. The vacuum is then released and a selected amount ofantimicrobial solution is injected between the two hand sections throughthe puncture opening in the outer glove section. The puncture opening isthen sealed.

In another preferred method, a multilayer glove may be made by dipping asubstantially hand-shaped form (e.g., a ceramic former) into a firstlayer-forming solution to form a first layer. The first layer may bedipped into a gas-releasing solution that releases gas when heated. Thefirst layer may then be dipped into a second layer-forming solution toform a second layer. Heat may be applied to either the first or thesecond layers (or both) such that gas is released from the gas-releasingsolution to form a gas-filled layer separating the first and secondlayers. The gas may then be replaced with an antimicrobial solution. Thefirst and second layers may be sealed together at the wrist.

"Multilayer" as used herein means more than one layer in, the finishedprotective covering. For instance, a preferred glove may include aninner layer, a middle layer filled with antimicrobial solution, and anouter layer. A covering may include only an inner layer and an outerlayer, thus producing a two layer covering. Such a covering in the formof a glove may be preferred by some doctors who currently wear twogloves to prevent infection. Alternatively, the glove may comprise aplurality of layers, with each layer including different materials.

The hand-shaped form may be dipped more than once to form the first andsubsequent layers. For instance, the form may be dipped twice or more insuccession in the same layer-forming solution to form a layer.

The first layer is substantially hand-shaped and ultimately forms theinner layer of a multilayer glove. The first and second layer-formingsolutions may include elastomers curable to form a rubbery elasticsurface. Preferably the layer-forming solutions include latex, but theymay also include neoprene or vinyl.

The layer-forming solutions may comprise a release agent. "Releaseagent" is defined to mean a compound that is added to reduce the"stickiness" or "tackiness" of the layers. Thus the release agent may beadded to reduce the tendency of the first layer to stick to the secondlayer. The layers may also be sprayed or coated with a release agent.Release agents may include soaps, silicone compounds, fluorinatedpolymers, or mixtures thereof.

Mold release agents commonly used to make vulcanized and unvulcanizedelastomers less sticky may be used as release agents. For instance, moldrelease agents such as talcum and stearate compounds may be used asrelease agents.

Preferred release agents include organosiloxane (i.e. silicone)compounds. A silicone is generally defined as a compound that includessiloxane polymers which are based on a structure including alternatesilicon and oxygen atoms, with organic radicals attached to the silicon.

A preferred release agent includes polydimethylsiloxane ("PDMS"). Thelayer-forming solutions and the gas-releasing solution may include about0.001-3.0 weight percent of a release agent such as PDMS, preferablyabout 0.005-0.200 weight percent, more preferably about 0.01-0.05 weightpercent, and more preferably still about 0.03 weight percent. PDMS soldunder the trade name "Dow Corning 200 Fluid Food Grade 350CS" (Midland,Mich., U.S.A.) may be used as a release agent. In addition, "SM 2128Silicone Emulsion" by General Electric Company (Waterford, N.Y., U.S.A.)may also be used as a release agent.

An excessive amount of PDMS (i.e., greater than about 5%) may causelarger and more numerous imperfections, thin areas, and pinholes to beformed in the layers. Moreover, an excessive amount of release agent inthe layers may increase the difficulty of sealing the layers to eachother.

Other silicone compounds that may be used as release agents includecompounds with PDMS structures. These PDMS structures may havedisubstituted silicon atoms mixed with monosubstituted silicon atoms.The monosubstituted silicon atoms may have pendent groups such as methylor phenyl. For instance, polyalkylene oxide modified diethylpolysiloxanemay be used as a release agent.

Other release agents include: (1) stearates such as stearic acid(preferably about 0.1-1.0 weight percent, more preferably about 0.2-0.7weight percent, and more preferably still about 0.25-0.50 weightpercent) and zinc, aluminum, ammonium, barium, calcium and magnesiumstearates, (2) fatty acids such as zinc oxide (preferably about 1.0-9.0weight percent, more preferably about 2.0-8.0 weight percent, and morepreferably still about 4.0-5.0 weight percent), fatty acid esters(preferably about 1.0-9.0 weight percent, more preferably about 2.0-8.0weight percent, and more preferably still about 4.0-5.0 weight percent),sodium salts of fatty acid esters, saponified and highly saturated fattyacids, and hydrogenated fatty acids, (3) ethylenes such asethylenebisoleamide (preferably about 0.1-2.75 weight percent, morepreferably about 0.3-1.2 weight percent, and more preferably still about0.3-0.5 weight percent), polyethylenes, ethylenebisstearamides, andethylenebismonomerates, (4) glycols such as polyethylene glycols andpolyalkylene glycols, and (5) other release agents such as ammoniumsalts of alkyl phosphate, polyethylenes, glycerine, vegetable oil soap,amorphous polypropylene, and straight chain alcohols.

In addition, release agents may include Mold Wiz AZN or Mold Wiz FFIH byAxel Plastic Research Laboratories, Inc. (Woodside, N.Y., U.S.A.)(preferably about 0.1-2.0 weight percent, more preferably about 0.1-1.0weight percent, and more preferably still about 0.25-0.75).

After dipping the hand-shaped form into the first layer-formingsolution, the first layer-forming material may be at least partiallydried or cured. In this manner the first layer is more stable, and maybe subsequently dipped without substantial wrinkling, oozing ordripping.

After forming the first layer, the first layer is dipped, preferablyfingers first, into a gas-releasing solution that releases gas whenheated. A "gas-releasing solution" is a solution that releasessufficient gas when heated to form a gas-filled layer separating thelayers.

The gas-releasing solution may include a coagulant. A coagulant isdefined to be a compound that coagulates a layer-forming solution sothat the layer-forming solution forms a thicker layer than it wouldnormally do otherwise. A coagulant is preferred because its presence mayenhance the formation of the second layer on top of the damp or wetfirst layer. Without the coagulant the second layer tends to formirregularly. The type and concentration of coagulant may influence thethickness of layers formed. Other factors that may also influence thethickness of the layers formed include the immersion time of the form inthe layer-forming solutions, and the viscosity of the layer-formingsolutions.

The coagulant may comprise the following: acetic acid, calcium chloride,calcium nitrate, formic acid, zinc nitrate, or a mixture thereof.Preferably the coagulant is calcium nitrate. The gas-releasing solutionmay comprise about 10-50 weight percent of a coagulant such as calciumnitrate, preferably about 10-30 weight percent, more preferably about15-25 weight percent, and more preferably still about 20 weight percent.The coagulant may also comprise a polysiloxane, which may also be mixedwith the other coagulant compounds mentioned above.

The gas-releasing solution may comprise a blowing agent. A blowing agentis a compound that is stable at room temperature but which decomposeswhen heated to vulcanization temperatures to release gas. Vulcanizationtemperatures are typically about 140°-180° C. Vulcanization temperaturesmay vary depending on the vulcanization system--i.e., depending on thecompounds vulcanized, the accelerators present, the vulcanization time,and other system-specific factors. Blowing agents are commonly used inthe production of sponges.

The blowing agent may include sodium hydrogen carbonate (i.e., sodiumbicarbonate). The gas-releasing solution may include about 5-25 weightpercent of a blowing agent such as sodium hydrogen carbonate, preferablyabout 10-14 weight percent, and more preferably about 12 weight percent.

The blowing agent may include ammonium carbonate. The gas-releasingsolution may include about 10-30 weight percent of a blowing agent suchas ammonium carbonate, preferably about 12-18 weight percent, and morepreferably about 15 weight percent.

Other blowing agents may be used. For instance, sodium bicarbonate incombination with a weak organic acid like tartaric, stearic- or oleicacid may be used. Sodium nitrite combined with ammonium chloride may beused. In addition, organic blowing agents such as (1) diazoaminocompounds (e.g. diazoaminobenzene), (2) azonitrile, (3)azodicarbonamide, (4) hydrazine derivatives (e.g. benzenesulfohydrazide,benzene-1,3-disulfohydrazide, diphenyloxide-4,4'-disulfohydrazide,p-toluenesulfonic acid hydrazide), (5) n-nitroso compounds (e.g.,n,n'-dinitrosopentamethylenetetramine andn,n'-dimethyl-n,n'-dinitrosophthalamide) (preferably about 20.0-80.0weight percent, more preferably about 40.0-75.0 weight percent, and morepreferably still about 65.0-70.0 weight percent), and (6) tartaric acid(preferably about 2.0-20.0 weight percent, more preferably about5.0-15.0 weight percent, and more preferably still about 10.0-12.0weight percent) may be used.

The toxicity and biocompatibility of the release agents, coagulants, andother compounds used in the solutions are also concerns when selectingsuch compounds for use for surgical gloves, condoms, etc.. In general itis preferred that such compounds be approved by the Food and DrugAdministration.

The gas-releasing solution may include a release agent such as discussedabove for the first layer-forming material. For example, thegas-releasing layer may include PDMS.

In a preferred embodiment only the gas-releasing solution includes arelease agent. In a preferred embodiment the form is dipped into a firstlayer-forming solution to a first point. The form is then dipped intothe gas-releasing solution to a second point that is short of the firstlayer-forming solution dip point. The form is then dipped into thesecond layer-forming solution to a third point that is beyond or pastthe second point. The third point may be before, at, or beyond the firstpoint. In a preferred embodiment the first and second layers may besealed together using the portions of these layers that have notcontacted the release agent (i.e., the portion of these layers that wasbeyond or past the second point). Alternately, the first and secondlayers may be rolled together to form a beaded edge. The presence of therelease agent in the portions of the first layer that were dipped intothe gas-releasing solution may decrease the stickiness of the first andsecond layers to each other. The absence of the release agent from theportions of the first and second layer that are to be sealed tends toimprove the seal between the layers.

The gas-releasing solution and the layer-forming solutions mayadditionally comprise an accelerator. An accelerator is preferablyincluded in the layer-forming solutions. An accelerator is a compoundthat is added to shorten the amount of time and/or heat required tovulcanize the layer-forming solutions.

The gas-releasing solution is preferably allowed to at least partiallydry. After the first layer is dipped into the gas-releasing solution, itis then dipped, preferably fingers first, into a second layer-formingsolution to form a second layer. The second layer-forming solution maycomprise the same components as described above for the firstlayer-forming solution. Preferably the second layer-forming solutioncomprises latex and PDMS, in the same preferred proportions as describedabove for the first layer-forming solution. Alternatively thelayer-forming solutions may not include a release agent such as PDMS.Omitting the mold release agents from the layer-forming solutions maytend to reduce the number and size of imperfections (such as pinholes)formed in the layers.

The first or second layers are heated such that gas is released from thegas-releasing solution to form a gas-filled layer separating the firstand second layers. Either or both of the first and second layers may beheated. Typically both the first and second layers are heated by placingthese layers in an oven. When formed, the gas-filled layer substantiallyseparates the first and second layers from each other. The release agenttends to facilitate separation of the layers. Without the release agentthe layers tend to stick together, and the gas tends to form pocketsinstead of a gas-filled layer. Certain layer-forming solutions may berelatively "unsticky," and with these solutions no release agent may berequired.

The first and second layers may be formed to comprise a wrist portionwith an edge. The first layer may then be sealed to the second layer atthe edge of the wrist portions of the first and second layers. The sealmay form a cylindrical beaded edge. Alternately, the layers may besealed together some distance from the edge.

In a preferred embodiment the antimicrobial solution replaces the gas inthe gas-filled layer.

The first layer is preferably dipped to a first point into thegas-releasing solution which is typically about 1-3 centimeters ("cm")(preferably about 2-3 cm) from the full length mark. The top of thewrist portion of the first layer is considered the "full length mark."The length of the wrist portion may vary, depending on the length ofwrist portion desired in the glove.

Preferably the gas-releasing solution is mixed and/or used at about5-15° C. (preferably about 8-12° C., and more preferably about 10° C.),which is a temperature wherein the amount of calcium nitrate coagulantmay be maximized in aqueous solutions. A preferred gas-releasingsolution is saturated with a coagulant such as calcium nitrate.Preferably the first and second layers are heated to a temperature ofabout 140°-180° C. to form the gas-filled layer. Gloves made by theabove-described method may be further washed to leach out remainingchemicals such as accelerators, gas-releasing solution, etc.

The gas-releasing solution and the layer-forming solutions may be in theform of a gel or a slurry. In a preferred embodiment the gas-releasingsolution is a slurry. A slurry may be acceptable so long as thegas-releasing solution is substantially evenly distributed. Agas-releasing slurry solution may be beneficial since it may have morerelease agent, coagulant, or blowing agent present than is present in asaturated gas-releasing solution. Preferably the gas releasing solutionis aqueous.

Another embodiment of the invention includes gloves made-according tothe methods described above.

An alternate method of making a multilayer glove comprises the step ofproviding a first glove on a hand-shaped form instead of forming thefirst layer as described above. The glove is made of similar materialsas described for first layer-forming solution. The glove acts as thefirst layer, and the steps described above for the first layer apply tothe glove. Preferably the glove is initially green (i.e., unvulcanized).

An alternate embodiment of the invention is a multilayer condom. Withthe exception of the form shape, the condom is made with substantiallysimilar materials and steps as outlined above for multilayer gloves. Thefirst layer is formed by dipping a substantially penis-shaped form intoa first layer-forming solution. The first layer is dipped into agas-releasing solution that releases gas when heated. The first layer isthen dipped into a second layer-forming solution to form a second layer.Heat is applied to the first or the second layer such that gas isreleased from the gas-releasing solution to form a gas-filled layerseparating the first and second layers.

The layer-forming solutions, gas-releasing solutions, release agents,coagulants, blowing agents, and other materials for the condom aresubstantially the same as for the gloves mentioned above. In addition, amultilayer condom may be made by providing a first (preferably green)condom on a penis-shaped form as an alternate way to form the firstlayer.

Another embodiment of the invention includes condoms made according tothe methods outlined above.

Another embodiment of the invention includes finger cots, and methods ofmaking finger cots. The finger cots are made in a substantially similarway as the condoms of the invention are made. With the exception of theform, the materials, steps, agents, solutions, etc. outlined above forcondoms will apply to finger cots. A finger cot is made with asubstantially finger-shaped form.

Referring now to FIGS. 4 and 5, a preferred embodiment of a condom 30 asprovided by the present invention is illustrated. The condom 30 includesan inner layer 32, and outer layer 34, and an impermeable seal 36between the inner and outer layers at the rim of the condom. A layer ofspermicidal solution 38 (thickness as described above), such asnonoxynol-9, is disposed between the inner layer 32 and outer layer 34.Nonoxynol-9 is preferred, as it is both spermicidal to reduce the riskof pregnancy and virucidal for protection against harmful viruses suchas HIV. The layers may be made of materials conventionally used formaking condoms.

In order to reduce the likelihood of the layers 32 and 34 from slippingon each other during use, the layers may be sealed together at aplurality of points. In the embodiment shown, the condom 30 is providedwith a plurality of circular heat stamped lines 40, dividing the condominto distinct compartments 41 along its length. In this arrangement, theprotective fluid 38 may be prevented from squeezing to the base of thecondom during use, as each heat stamped line 40 will restrict fluid flowbetween adjacent compartments 41. The heat stamped lines may be formedby heating and pressing the inner and outer layers together at thedesired places for a sufficient length of time for a seal to form.

Referring now to FIG. 6, a preferred embodiment of a finger cot 50 isillustrated. Similar to the surgical glove described above, the fingercot 50 includes an inner layer, an outer layer 54, an impermeable seal56 between the inner and outer layers, and a layer of antimicrobialsolution (thickness as described above) disposed between the layers. (Itshould be noted that a sectional view of the sidewall of the finger cotwould look substantially similar to FIG. 5). The preferred materials foruse as the layers and antimicrobial solution discussed above inconnection with surgical gloves also apply to the finger cot 50.

Since finger cots are conventionally used for procedures such as rectalor vaginal examinations, it is desirable to seal the inner layer 52 andouter layer 54 together at a plurality of points to reduce thelikelihood of disassembly during use. In the embodiment shown, thefinger cot 50 is heat stamped with several circular lines 60,compartmentalizing the finger cot into isolated sections 61. As with thecondom described above, this embodiment prevents the antimicrobialsolution from accumulating at the base of the finger cot during use.

The following experiment was designed to demonstrate the capillarycoupling force exerted by a liquid layer between two latex surfaces as afunction of the thickness of the liquid layer. This was accomplished bymeasuring the average failure load ("AFL") in g/cm², between two glasscarriers coated with vulcanized latex, having a fluid layer of varyingthickness therebetween.

FIG. 7 illustrates the apparatus used in the experiment. Two pieces oflatex material 104 and 106 were glued onto the surface of two glasscarriers 100 and 102, respectively. The pieces of latex were obtainedfrom Travenol Triflex Sterile Latex Surgeons Gloves, size 8.5, in whichpowder had been removed by washing three times in 2 liters aqua bidet.The latex layers 104 and 106 were each 0.18 mm thick, while each glasscarrier 100 and 102 was 6 mm thick.

Glass carrier 100 was mechanically connected to a micrometer 108 with0.01 mm resolution. The glass carriers were kept in substantiallyparallel alignment during movement. The micrometer 108 was driven by astepping motor 110 at a rate of 1 mm/min.

Glass carrier 102 was preweighted with 300 g and connected to a rapidlyindicating electronic balance 112. The contact area between the twocarriers 100 and 102 was 2 in² (˜25.81 cm²).

Volumes ranging from 10 μl to 500 μl of colored bactericidal fluid 114,were pipetted onto the surface of carrier 102, and carrier 100 waslowered until the liquid 114 covered the entire contact area.

Carrier 100 was then lifted at a constant time rate by the stepper motor110 via the micrometer 108. The maximum decrease in weight, indicated bythe electronic balance 112, was reached shortly before rupture of theliquid layer 114 and noted.

Each experiment for a specific liquid volume was repeated seven times.

The results of the experiment are shown in Table 1 and FIG. 8. Themaximum AFL was reached at a liquid volume of around 100 μl (˜0.039 mmfluid layer thickness). The AFL approached zero at volumes above 300 μl(˜0.116 mm thick).

For comparison, the last column of Table 1 gives the required liquidvolume, corresponding to the given liquid layer thickness, for a glovesize 8.5 (surface area ˜650 cm²). Thus, for example, to obtain a fluidlayer thickness of 0.039 mm between two size 8.5 gloves would require afluid volume of about 2.518 ml.

                                      TABLE 1                                     __________________________________________________________________________            DISTANCE               EQUIVALENT                                             BETWEEN CARRIERS                                                                           AVERAGE   LIQUID VOLUME                                  LIQUID  (LIQUID LAYER                                                                              FAILURE LOAD                                                                            FOR GLOVE                                      VOLUME (μl)                                                                        THICKNESS) (mm)                                                                            (g/cm.sup.2)                                                                            (ml/650 cm.sup.2)                              __________________________________________________________________________    10      0.004        0.000     0.252                                          15      0.006        0.000     0.378                                          20      0.008        0.000     0.504                                          25      0.010        0.697     0.630                                          30      0.012        0.969     0.756                                          35      0.014        1.124     0.881                                          40      0.015        1.434     1.007                                          45      0.017        1.860     1.133                                          50      0.019        2.402     1.259                                          55      0.021        2.867     1.385                                          60      0.023        3.371     1.511                                          65      0.025        3.487     1.637                                          70      0.027        3.681     1.763                                          75      0.029        3.952     1.889                                          80      0.031        4.184     2.015                                          85      0.033        4.339     2.141                                          90      0.035        4.456     2.267                                          95      0.037        4.494     2.392                                          100     0.039        4.611     2.518                                          125     0.048        3.719     3.148                                          150     0.058        2.751     3.778                                          175     0.068        1.860     4.407                                          200     0.077        1.162     5.037                                          225     0.087        0.814     5.666                                          250     0.097        0.504     6.296                                          275     0.107        0.310     6.926                                          300     0.116        0.116     7.555                                          350     0.136        0.000     8.814                                          400     0.155        0.000     10.074                                         450     0.174        0.000     11.333                                         500     0.194        0.000     12.592                                         __________________________________________________________________________

The instant invention has been disclosed in connection with specificembodiments. However, it will be apparent to those skilled in the artthat variations from the illustrated embodiments may be undertakenwithout departing the spirit and scope of the invention. For example, inconnection with jobs where it is required that gloves be discarded aftera certain amount of use, e.g. four hours, an absorption indicatingsubstance might be placed between the glove layers to, e.g., changecolors upon a certain degree of absorption.

I claim:
 1. A method for making a multilayer glove, comprising the stepsof:dipping a substantially hand-shaped form into a first layer-formingsolution to form a first layer on the hand-shaped form; dipping thefirst layer into a gas-releasing solution that releases gas when heatedto deposit a single substantially continuous layer of the gas-releasingsolution on the first layer; dipping the first layer into a secondlayer-forming solution to form a second layer, such that thegas-releasing solution is disposed between the first and second layers;and heating the first or second layer such that gas is released from thegas-releasing solution to form a single substantially continuousgas-filled layer separating the first and second layers.
 2. A method formaking a multilayer glove, comprising the steps of:dipping asubstantially hand-shaped form into a first layer-forming solution to afirst point on the hand-shaped form to form a first layer on thehand-shaped form; dipping the first layer to a second point on thehand-shaped form short of the first point into a gas-releasing solutionthat releases gas when heated to deposit a single substantiallycontinuous layer of the gas-releasing solution on the first layer;dipping the first layer to a third point on the hand-shaped form locatedpast the second point into a second layer-forming solution to form asecond layer, such that the gas-releasing solution is disposed betweenthe first and second layers; and heating the first or second layer suchthat gas is released from the gas-releasing solution to form a singlesubstantially continuous gas-filled layer separating the first andsecond layers.
 3. The method of claim 1, further comprising the step ofreplacing gas in the gas-filled layer with an antimicrobial solution. 4.The method of claim 2, further comprising the step of replacing gas inthe gas-filled layer with an antimicrobial solution.
 5. The method ofclaim 1 wherein the first and second layers are both formed to comprisea wrist portion with an edge, and further comprising the step of sealingthe first layer to the second layer at the edge of the wrist portions.6. The method of claim 5 wherein an antimicrobial solution is sealedbetween the first layer and the second layer.
 7. The method of claim 2wherein the first and second layers are both formed to comprise a wristportion with an edge, and further comprising the step of sealing thefirst layer to the second layer at the edge of the wrist portions. 8.The method of claim 7 wherein an antimicrobial solution is sealedbetween the first layer and the second layer.
 9. The method of claim 1wherein the first layer-forming solution comprises a release agent. 10.The method of claim 1 wherein the second layer-forming solutioncomprises a release agent.
 11. The method of claim 1 wherein thegas-releasing solution comprises a release agent.
 12. The method ofclaim 1 wherein the first layer-forming solution comprises a siliconecompound.
 13. The method of claim 1 wherein the second layer-formingsolution comprises a silicone compound.
 14. The method of claim 1wherein the gas-releasing solution comprises a silicone compound. 15.The method of claim 1 wherein the first layer-forming solution comprisespolydimethylsiloxane.
 16. The method of claim 1 wherein the secondlayer-forming solution comprises polydimethylsiloxane.
 17. The method ofclaim 1 wherein the gas-releasing solution comprisespolydimethylsiloxane.
 18. The method of claim 1 wherein the firstlayer-forming solution comprises about 0.001-3.0 weight percentpolydimethylsiloxane.
 19. The method of claim 1 wherein the firstlayer-forming solution comprises about 0.005-0.2 weight percentpolydimethylsiloxane.
 20. The method of claim 1 wherein the firstlayer-forming solution comprises about 0.01-0.05 weight percentpolydimethylsiloxane.
 21. The method of claim 1 wherein the secondlayer-forming solution comprises about 0.001-3.0 weight percentpolydimethylsiloxane.
 22. The method of claim 1 wherein the secondlayer-forming solution comprises about 0.005-0.2 weight percentpolydimethylsiloxane.
 23. The method of claim 1 wherein the secondlayer-forming solution comprises about 0.01-0.05 weight percentpolydimethylsiloxane.
 24. The method of claim 1 wherein thegas-releasing solution comprises about 0.001-3.0 weight percentpolydimethylsiloxane.
 25. The method of claim 1 wherein thegas-releasing solution comprises about 0.005-0.2 weight percentpolydimethylsiloxane.
 26. The method of claim 1 wherein thegas-releasing solution comprises about 0.01-0.05 weight percentpolydimethylsiloxane.
 27. The method of claim 1 wherein the firstlayer-forming solution comprises latex.
 28. The method of claim 1wherein the second layer-forming solution comprises latex.
 29. Themethod of claim 1 wherein the gas-releasing solution comprises acoagulant.
 30. The method of claim 29 wherein the coagulant is aceticacid, calcium chloride, calcium nitrate, a polysiloxane, formic acid, orzinc nitrate.
 31. The method of claim 1 wherein the gas-releasingsolution comprises calcium nitrate.
 32. The method of claim 1 whereinthe gas-releasing solution comprises about 10-50 weight percent calciumnitrate.
 33. The method of claim 1 wherein the gas-releasing solutioncomprises about 10-30 weight percent calcium nitrate.
 34. The method ofclaim 1 wherein the gas-releasing solution comprises about 15-25 weightpercent calcium nitrate.
 35. The method of claim 1 wherein thegas-releasing solution comprises a blowing agent.
 36. The method ofclaim 1 wherein the gas-releasing solution comprises sodium hydrogencarbonate.
 37. The method of claim 1 wherein the gas-releasing solutioncomprises about 5-25 weight percent sodium hydrogen carbonate.
 38. Themethod of claim 1 wherein the gas-releasing solution comprises about10-14 weight percent sodium hydrogen carbonate.
 39. The method of claim1 wherein the gas-releasing solution comprises ammonium carbonate. 40.The method of claim 1 wherein the gas-releasing solution comprises about10-30 weight percent ammonium carbonate.
 41. The method of claim 1wherein the gas-releasing solution comprises about 12-18 weight percentammonium carbonate.
 42. The method of claim 1 wherein the gas-releasingsolution is about 8°-12° C.
 43. The method of claim 1 wherein thegas-releasing solution is about 5-15° C.
 44. The method of claim 1,further comprising the step of at least partially drying the first layerbefore dipping into the gas-releasing solution.
 45. The method of claim1, further comprising the step of at least partially drying thegas-releasing solution before dipping into the second layer-formingsolution.
 46. The method of claim 7 wherein the first point is about 1-3centimeters from the edge of the wrist portion.
 47. A method of making amultilayer glove, comprising the steps of:providing a first glove on asubstantially hand-shaped form; dipping the first glove into agas-releasing solution that releases gas when heated to deposit a singlesubstantially continuous layer of the gas-releasing solution on thefirst glove; dipping the first glove into a layer-forming solution toform an outer layer, such that the gas-releasing solution is disposedbetween the first glove and the outer layer; and heating the first gloveor the outer layer such that gas is released from the gas-releasingsolution to form a single substantially continuous gas-filled layerseparating the first glove and the outer layer.
 48. The method of claim47, further comprising the step of replacing the gas in the gas-filledlayer with an antimicrobial solution.